Building block structures and components



Nov. 6, 1962 BUILDING BLOCK STRUCTURES AND COMPONENTS Filed July 28, 1958 3 Sheets-Sheet l INVENTOR. HAROLD F PooF 32,, BM 4m H. F. RooF 3,061,979

' H. F. ROOF BUILDING BLOCK STRUCTURES AND COMPONENTS Filed July 28, 1958 Nov. 6, 1962 3 Sheets-Sheet 2 HAROLD l-T POOP A TI'OE/VE'VS H. F. OF

Nov. 6, 1962 3,061,979

BUILDING BLOCK STRUCTURES AND COMPONENTS Filed July 28, 1968 3 Sheets heet 3 F w W R. m F 4 r 0 A 6 KM v w hired 3,061,979 Patented Nov. 6, 1%52 3,061,979 BUILDING BLOCK STRUCTURES AND CONHUNENTS Harold F. Roof, Anacortes, Wash. (1611 Chehalis Ave, Chehalis, Wash.) Filed July 28, 1958, Ser. No. 751,360 11 Claims. (Cl. tl389) This invention relates to improvements in techniques and components for the erection of structures from building blocks. A broad object hereof is to provide such improvements for essentially mortarless construction using concrete blocks. The invention is herein illustratively described by reference to the presently preferred forms and usages thereof; however, it will be recognized that certain modifications and changes with respect to details may be made without departing from the underlying features involved.

In the references herein to the invention as constituting a technique for erecting mortarless building block structures, it should be noted that this does not necessarily imply that mortar or other hinder or sealer substance may not be used in such structures. It is rather the intention to make clear that the using of mortar as a cementing material binding the blocks together is unnecessary and, in fact, in most cases is undesirable since the parts are precision made and the use of mortar in the usual quantities could, except in the hands of very skilled workmen, create problems in satisfying dimensional specifications for the structures. However, thin mortar, mastic or other flowable cementitious filler substance may be used to advantage if desired in all cases where additional sealing of joints between blocks, beyond that afforded by the novel interlocks themselves which, in most structures, serve as flashing elements.

Others heretofore have considered mortarless systems of block construction. However, most if not all of those proposals were unduly complex and expensive, either in their manufacture or in their use in construction, or both. Most required an unduly large number of assorted special block and interlock forms in order to meet the specific requirements of different structure and different parts of a structure. Most were limited in their applicability to vertical walls or to fully supported horizontal walls. Few, if any, were entirely suited for satisfying the close tolerance requirements imposed by a mortarless method of construction using precision interfitting parts, because of difficulties in manufacture and use.

The present invention, in addition to overcoming the above-mentioned difliculties, is directed to novel improvements which may employ comparatively simple, compact, light weight, easily and rapidly assembled and highly versatile interlock elements and cooperable concrete blocks.

Compact stacking or nesting of the interlock elements for purposes of shipment, storage and handling is also an objective. Strength of the structures far in excess of panels using mortar is a further objective.

A specific object herein is the provision of low-cost interlock means and blocks. In this regard, versatile standardized sheet metal or equivalent interlock members are used, which may readily be cut to desired lengths and otherwise prepared or formed on the job when necessary for extending a panel around corners, into intersections and for various special applications.

Positive interlock with each block and between intersecting or joined panels of blocks, adaptability to horizontal or inclined panel construction, and to suspended ceiling panel construction, and similar objectives are also within the purview of this invention.

In addition, the novel interlock sections of this invention provide a seal or flashing in all block joints preventing ingress of water, and sealing against drafts from without and against loss of heated air from within.

Features of the invention lie in the provision of Z-section interlock rails and Z-section interlock risers, respectively having fastener slots in their webs and securing tabs on their ends engageable in said slots, by means of which rigid interconnected frames are formed around the individual blocks as they are successively laid in place, such blocks being narrowly slotted around their peripheries to snugly accommodate the interlock flanges. Another feature resides in the provision of two parallel slots around the periphery of each block, spaced apart by the web width of the Z-Section interlocks, whereby the blocks may face either side up or may be swung end-for-end, or whereby the interlocks may be swung end-for-end, without affecting the fitted relationship of the parts. This expedites the laying up procedure and reduces the chances of error.

These and other features, objects and advantages of the invention will become more fully evident from the following description thereof by reference to the accompanying drawings.

FIGURE 1 is a perspective view showing lengths of interlock rails and two interposed, interlock risers, such interlocks being relatively separated somewhat from the spatial relationship which they occupy when assembled in a straight panel structure.

FIGURE 2 is a perspective view of the preferred form of building block for straight panel structures.

FIGURE 3 is a vertical sectional view showing a lower portion of a straight wall panel according to the invention, and a supporting footing for such wall.

FIGURE 4 is a perspective view of lengths of interlock rail interconnected by an interlock riser in their assembled relationship.

FIGURE 5 is a perspective View of the Wall portion illustrated in FIGURE 3 in process of erection.

FIGURE 6 is a perspective view of a preferred corner or wall intersection block.

FIGURE 7 is a perspective view of a specially cut and bent length of Z-section interlock rail adapting it for a wall corner application.

FIGURE 8 is a perspective view of blocks in a tier at a wall corner, to illustrate the corner detail.

FIGURE 9 is an exploded view illustrating the preferred T-intersection assembly and technique of construction.

FIGURE 10 is a simplified view showing a suspended ceiling technique employing features of the invention.

FIGURE 11 is a simplified view showing a beamtype ceiling panel construction according to features of the invention.

Referring to the drawings, tWo partial lengths of interlocks rails 1d are shown in conjunction with two interlock risers 12. These interlocks are preferably formed of Z-section sheet metal, the rails comprising a flat web 10a and oppositely directed flanges 10b and adjoined to opposite edges of the web. Similarly the risers comprise a web 12a and oppositely directed flanges 12b and 121:. At regular intervals along the length of the rail Webs 10a, transverse slots 16a are formed therein such as by breaking the metal along a transverse shear line under pressure of a forming die which offsets the metal at one side of the breakout of the plane of the main web, as shown. Cooperable with these slots are end tabs 12a on the riser webs 12a, which tabs are adapted to pass through oppositely located slots in the parallel rails and to be bent over beneath the offset portion struck up from the rail webs, thereby to be accommodated within the pocket formed by such offset portion. Preferably the risers are formed such that the web and one flange, such as the flange 12b,

are of the same length and are cut off at right angles to their length whereas the other flange, such as 120, is foreshortened at both ends by an amount equal substantially to the width of the rail flanges. Thus, with the flange c of the upper of the two rails directed downwardly and with a flange, such as 1%, of the underlying rail directed upwardly in the same plane as the downwardly directed flange, the risers may be placed between the rails and the tabs locked in position, with the shortened riser flange 120 received between and with its ends abutting the edges of said coplanar rails, to lie in the same plane therewith. The opposite riser flanges 121) then lie in the common plane of the remaining rail flanges. This is the assembled relationship of the rails and risers, as shown in FIGURES 3 and 4, for example.

The spacing between slots Illa along the length of each rail corresponds preferably to one-half the length of the concrete blocks with which these interlocks are to be used. If desired, for some applications, this spacing may be made equal to the length of the blocks assuming the blocks are to be laid in columnar instead of Staggered relationship in alternate courses or tiers. In other cases this spacing may be decreased below that equal to one-half the minimum block length. It will be seen that rigid interlocking frames are formed by the interconnected rails and risers, such frames being arranged in successive tiers or courses corresponding to the arrangement of blocks to be laid in the panel and held within the respective frames. Such rails and risers are assembled one after the other with the successive laying of the blocks in tiers as will be more fully described hereinafter.

Referring to FIGURE 2, a typical block is depicted in a standard rectangular form, this block being designated 14 and comprising parallel rectangular side faces 14a, rectangular top and bottom faces 14b, and rectangular or square end faces 140. The block length equals twice its height whereas its width or thickness equals its height. It will be recognized, however, that the shape and dimensional proportions may vary for different applications, although usually the width will equal a sub-multiple, normally one-half, of the length. Such block may be made of any suitable material but for most applications of the invention will be formed of a light weight concrete such as a vermiculite and Portland cement aggregate. Each block has at least one groove or narrow slit 14d extending around its periphery in a plane which is offset from the longitudinal block median plane by an amount equal to substantially one-half the width of the interlock rails and risers. Preferably there is also a second and similar slit 14e offset by the same amount from the opposite side of such median plane. The two slits usually have a uniform depth which is substantially at least equal to the width of the rail and riser flanges which are to be accommodated therein. Preferably, as shown best in FIGURE 3, the block surface areas, on all faces occupied by the grooves 14d and 14e, are recessed back of the general surface by an amount approximating the thickness of the webs of the interlock rails and risers so as to permit face-to-face contact of adjoining blocks without interference from the interposed interlocks.

In the construction of a straight vertical Wall panel by means of this invention, the procedure is typically as illustrated in FIGURES 3 and 4. A suitable footing 16 is laid having securing means such as the anchor bolts 16a embedded in the top thereof. A channel 18 with its flanges directed upwardly at a lateral spacing equal to the spacing between block grooves 14d and 14a is secured by nuts 16b to the top face of the footing. Preferably the web of the channel 18 is slotted at intervals along its length in the same manner and to the same ends as the slotting of the interlock rail webs, so that in the process of installing the channel 18 the tabs of the interlock risers 12 for the first tier of blocks are bent and secured to the footing with the risers in position. For the purpose of this first tier, one end of the riser flange 12b may be shortened by the amount necessary to accommodate the channel web occupying the same plane. Alternatively, the channel web 18 may be replaced by an angle section the flange of which lodges in only one of the block grooves at the bottom of the tier, and in this case unmodified risers 12 may be used. With the anchor channel 13 installed and with the risers 12 for the first tier of blocks secured in place projecting upwardly from the channel, the successive blocks in the tier are installed by sliding them down into the spaces between the successively adjacent risers with the riser flanges 12b and being received in the end face slots 14d aind 14c, respectively, and with the footing chan nel flanges being received in the bottom face grooves in the blocks. Upon laying of the first tier of blocks, T1, the succeeding step is to place the rail R1. This is done by inserting the downwardly projecting rail flange into one of the aligned grooves of the blocks 14:! or 14a, and by passing the upstanding tabs 12a of the installed risers through appropriate slots in the rail web. This anchors the rail web in place. Before or after this first rail R1 is installed the tabs of the risers U2 for the succeeding tier of blocks may be secured to the rail. Flexibility of the interlock sheet metal sections usually permits installing the risers after the underlying rail is installed to which they are to be connected. This is done by tilting the riser downwardly until its tab can be forced into the slot, with the riser approaching parallel relationship with the installed rail, whereupon straightening of the riser upwardly into a vertical position bends the tab and permits the lowermost end edge of the foreshortened flange 12c of the riser to rest upon the upper edge of the upwardly projecting flange of the installed rail. The next higher tier of blocks T2 is then installed in the same manner by sliding the blocks into position and lodging the interlock rail and riser flanges in the appropriate block grooves. The entire process moves ahead very rapidly and a strong interlocking wall structure is easily achieved.

The blocks are in facc-to-face contact and by manufacturing these blocks in accordance with known precision molding techniques a highly precise structural result is possible. If desired, the grooves or slits 14d and Me in the blocks may be filled with a mastic, mortar or other sealing substance prior to or in connection with laying the blocks so that when the interlock rail and riser flanges are inserted in these grooves a completely weathertight seal will be obtained. The rails and risers themselves serve as a flashing, however, largely if not completely preventing flow of air or moisture through the joints. A tight fit of the interlock flanges in the block grooves is desirable not only for this purpose but for strengthening and rigidifying the wall structure. Alternatively, or in addition, sealing substance may be spread over the contacting faces of the blocks. However, it is desirable in practically all cases to minimize the amount of mortar or other substance placed between the blocks in this manner and it is much preferred that the blocks be formed in a precision manner to fit together properly and without need of any mortar substance in order to compensate for discrepancies.

In FIGURE 6 a modified block is shown adapted especially for carrying a block wall around a corner as shown in FIGURE 8 or for use in forming a T-intersection as shown in FIGURE 9. This block 20 is preferably of the same dimensions as the wall block 14. It has opposite end faces 20c, side faces 20a and top and bottom faces 26b. Its two interlock grooves 20d and 20a, instead of extending around the entire periphery of the block in a common plane, extend: up and down along the entire length of one end face 200 and from such face approximately three-quarters of the length of the block toward the opposite end face, along the top and bottom faces 20b, thence at right angles to the edge of such top and bottom faces, thence vertically along one side face 20a, as shown. The preferred technique for incorporating such a block in a corner construction, as shown in FIGURE 7, is to employ a continuous length of inter- 5. lock rail 22 (FIGURE 7) bent into a right angle form by cutting a 90 degree notch out of the rail web 22a at the location of the bend, and removing the included metal of the flange, such as flange 22c, at the inside of the desired bend. The location of the notch is selected having due regard for the relative locations of the tab-receiving web slots 22a. Thus, one of the flanges, such as the lowermost flange 22c, fits into one of the grooves 20d or 2% of the corner block and extends into the aligned grooves 14d or 14e of the adjoining wall blocks, Whereas the oppositely projecting flange 22b, is adapted for insertion in the other of the two corner block grooves in the tier of blocks next laid. In this manner the sections of wall joined at right angles at the corner are tied together positively by means of the interlock rails.

The preferred manner of using features of the invention to form a T-section wall is shown in FIGURE 9. The straight section of wall W is for-med in the usual manner and by blocks of the type described in connection with FIGURE 2. However, at the location where the intersecting wall I is to meet the wall W, a somewhat modified type of block is employed, at least in alternate courses, such block being designated 30. This block is similar to the blocks 14 but comprises grooves 30d and 30e formed in the one side face 30a thereof, that side which faces the intersecting wall I. In addition, these grooves 30d and 30:; extend part way across the top and bottom faces of the blocks 30 by an amount at least equal to the width of the flanges of the interlock risers 12 so that risers may be installed between the side faces of the blocks 30 and the adjoining end faces of the blocks 14 in the intersecting wall I, as shown. The interlock rails which are incorporated in and stiffen the running wall W prevent lateral shifting of the blocks in this wall, hence no lateral tie between the intersecting wall and the running wall W is necessary, preventing separation of these two walls at their joint. However, lateral shifting of the intersecting wall I along the length of the running wall W is prevented by the interlock constituted between the flanges of the interposed interlock risers 12 and at least selected abutting blocks of the respective walls, as indicated. The arrows in the figure illustrate the relative directions of movement of the parts being assembled in the process of forming the T-intersection. Other detail techniques may be employed folio-wing the same general or basic principles of the invention.

In somewhat similar manner intersections between two running walls may be formed (not shown). In this instance the blocks 30 may be used as before, with thein positions reversed on selected tiers so that the respective sections of wall I on opposite sides of the equivalent running wall are tied to the latter through selected blocks 39 in the running wall. Alternatively, blocks 30 may be formed with side grooves 30d and 30:: on both side faces thereof so that the two sections of intersecting wall may be tied to the running wall through the same block or blocks therein.

In FIGURE 10 there is shown a method of produc ing a suspended ceiling using suspension strips or rods 40, the upper ends of which are suitably anchored to the roof structure of the building (not shown) and the lower ends of which are welded or otherwise secured to the interlock sections 42 which are the equivalent of the interlock rails 10 in the vertical wall embodiments previously described. The method of assembling a suspended ceiling panel using this principle of construction is generally the same as in the case of assembling a vertical wall except the absence of gravity forces holding the blocks in compacted relationship must be, of course, replaced by a suitable means preventing spreading thereof, thereby preventing the interlock flanges from dislodging from the complemental grooves in the block faces. Where necessary the blocks through or between which the suspension strips 4% pass are notched usually on the job, to allow room for the strips to pass without separating the blocks.

In FIGURE 11 is illustrated a beam type ceiling using the same principle. In this instance the entire strength of the panel as a beam depends upon the stiffness of the interlock rail sections therein. The span which may be formed by such a structure is, of course, limited accordingly but by use of somewhat heavier gauge (or wider) interlock rail sections the beam type ceiling may be erected with fairly long spans, particularly if relatively thin blocks are used, and thereby provide an economical and fireproof ceiling panel structure. In the process of assembling such a beam type ceiling panel the successive placement of blocks and riser interlocks as the blocks are laid is simplified by the fact that the cantilever strength of the risers when their tabs are locked to the slotted portions of the previously laid interlock rails is suflicient to support the weight of themselves and the individual blocks engaged by them until the next successive interlock rail can be laid and tab-secured to the risers and thereby support the blocks in that tier along both of their longitudinal edges. This greatly simplifies and expedites the process of laying up such a beam type ceiling panel. Similar considerations are applicable to the suspension type ceiling illustrated in FIGURE 10 although in that instance greater spans may be covered because of the supporting strength of the suspension strips or rods 40 secured to the interlock rails at suitable intervals.

The invention has thus been described in its preferred embodiment and mode of operation. It 'will be recognized that the interlock rails and riser elements may be made of relatively inexpensive material, such as galvanized mild or cold rolled sheet steel and may be produced in any desired lengths with standard spacings between the slots in the rails and with standard lengths for the risers depending upon the block dimensions to be used. Such rail sections may be cut on the job to any desired length by the use of metal band shears and may be bent or otherwise formed, as for example in the making of the corner illustrated in FIGURE 7, on the job and with available conventional tools. The Z-section formation of these relatively light weight rails and risers enables them to be nested and stacked in bundles tied together for convenient handling, shipment and storage. The blocks themselves may be precast with the grooves in them or may be slotted on the job although it is by far preferred that they be precast in completed form in order to save time on the job. Light weight pumice or vermiculite aggregate blocks, however, do lend themselves to cutting with power saws and it is not altogether impracticable to do the slotting on the job in certain instances.

It will be recognized that in wall structures the rails may be installed running vertically instead of horizontally if desired, and that this may be done with staggered block arrangements or with the blocks in rows, or otherwise.

These and other aspect of the invention will be recognized 'by those skilled in this art from the foregoing description and illustrations.

I claim as my invention:

1. A panel structure comprising successive rows of building blocks, elongated Z-section interlock rails extending lengthwise of and interposed individually between adjacent rows, said rails being of a length to overlap a plurality of blocks in each of the adjacent rows, the blocks in each of adjacent rows having aligned slots therein extending lengthwise of the row, and each interlock rail having a web disposed parallel to and lying between the adjacent faces of the blocks in the respectively adjacent rows, such interlock rail further having a flange extending along one edge of said Web, projecting at right angles thereto, and lodged in aligned slots of said plurality of blocks in one such row and a flange directed oppositely in relation to the first flange, from the opposite edge of said Web and lodged in aligned slots of the plurality of blocks in the adjacent row, and a plurality of Z-section interlock risesrs interposed individually between mutually adjacent blocks in the same row, said interlock risers having webs and oppositely directed flanges on respectively opposite sides of such Webs, the mutually adjacent block faces having slots therein receiving such flanges, said risers being connected to the interlock rails on each side of the respective rows in which said interlock risers are located.

2. The panel structure defined in claim 1, wherein the webs of the interlock rails have openings therein at intervals along their length coinciding with the locations of the interfaces between blocks in the same row, and the webs of the interlock risers have locking elements on their opposite ends lockingly engageable with the rail webs by lodging such elements in the rail web openings.

3. The panel structure defined in claim 2, wherein the interlock rails and risers are of sheet metal construction and the locking elements in the ends of the riser webs comprise bendable tabs projecting endwise therefrom for insertion through the rail web openings and for bending over subsequently thereto.

4. The panel structure defined in claim 3, wherein the rail web openings comprise transversely extending slots in the web, the rail web adajcent one side of each such slot being offset from the plane of the web to form a pocket adapted to at least partially accommodate an interlock riser bent tab therewithin.

5. The panel structure defined in claim 4, wherein the slotted faces of the individual blocks are recessed in areas on which the webs of the interlock rails and riser are superimposed, by an amount at least substantially as great as the thickness of such webs.

6. The panel structure defined in claim 2, wherein the interlock rails and risers are of sheet metal and the ends of the riser webs have bendable tabs projecting endwise therefrom, the webs of the interlock rails having slots therein adapted to pass the respective riser tabs whereupon bending over of said tabs secures the risers to the rails.

7. The panel structure defined in claim 6, wherein the slotted faces of the individual blocks are recessed in areas on which the webs of the interlock rails and risers are superimposed, by an amount at least substantially as great as the thickness of such webs.

8. The panel structure defined in claim 6, wherein the rail web adjacent one side of each such slot therein is offset from the plane of the web to form a pocket adapted to at least partially accommodate an interlock riser bent tab therewithin.

9. The panel structure defined in claim 8, wherein the slotted faces of the individual blocks are recessed between the parallel slots therein by an amount at least substantially as great as the thickness of such webs.

10. A panel structure comprising successive rows of building blocks, elongated Z-section interlock rails extending lengthwise of and interposed individually between adjacent rows, said rails being of a length to overlap a plurality of blocks in each of the adjacent rows, the blocks in each of adjacent rows having parallel aligned slots therein extending lengthwise of the row and spaced by equal distances from the midplane, and each interlock rail having a web of a width substantially equal to said slot spacing, disposed parallel to and lying between the adjacent faces of the blocks in the respectively adjacent rows, such interlock rail further having a flange extending along one edge of said web, projecting at right angles thereto, and lodged in aligned slots of said plurality of blocks in one such row and a flange directed oppositely in relation to the first flange, from the opposite edge of said web and lodged in aligned slots of the plurality of blocks in the adjacent row, the pairs of slots in the individual blocks extending around their entire periphery in parallel common planes respectively, and a plurality of Z-section interlock risers interposed individually between mutually adjacent blocks in the same row, said interlock risers having webs and oppositely directed flanges on respectively opposite sides of such webs lodged in slots in the mutually adjacent block faces, and said risers being connected to the interlock rails on each side of the respective rows in which said interlock risers are located.

11. A structural frame for use with peripherallygrooved building blocks, comprising a pair of flat-webbed elongated rails having transverse slots in the webs thereof and extending in spaced parallel relationship to one another with their longitudinal axes lying in a common vertical plane, and a pair of flat-webbed elongated risers extending perpendicularly between the rails in spaced relation to one another with their longitudinal axes lying in said plane and their ends engaged in oppositely disposed transverse slots in said rails to form a closed frame for the block, the longitudinally extending edge portions of the rails being bent angularly to form flanges thereon with the rail flanges on one side of the frame being bent inwardly of the frame and toward one another and the rail flanges on the other side of the frame being bent outwardly thereof and away from one another, thus giving the rails oppositely disposed Z-sections, and the longitudinally-extending edge portions of the risers being bent angularly to form flanges thereon with the riser flanges on one side of the frame being bent in a common direction parallel to said plane and on the other side of the frame being bent in the opposite direction, thus giving the risers similarly disposed Z-sections, the riser flanges on each side of the frame extending in end contact with the rails and in substantially coplanar relationship with the respective rail flanges on the respective frame side, whereby the frame, when its inwardly-directed flanges are in groove-engagement with the block, presents outwardlydirected flanges about its perimeter engageable with one or more other blocks.

References Cited in the file of this patent UNITED STATES PATENTS Austria May 26, 1924 

